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Silane XLPE Compound of Sioplas Method for Wire and Cable up to 3kV
This material is a warm water crosslinkable polyethylene insulation compound consisting of Compound A and Compound B, specifically designed for the production of XLPE (cross-linked polyethylene) insulated power cables. It is particularly suitable for low voltage (LV) cable applications requiring high thermal stability, excellent electrical properties, and consistent crosslinking performance.
| Component | Composition | Function |
|---|---|---|
| Compound A | High-quality polyethylene resin + imported silane coupling agent | Provides the base polymer matrix; the silane agent enables moisture-initiated crosslinking |
| Compound B | Organotin catalysts + antioxidant agents | Catalyzes and accelerates the crosslinking reaction; antioxidants protect against thermal degradation during processing and long-term service |
The manufacturing process employs a loss-in-weight feeder system, which ensures:
Stable and precise control of the component ratio (Compound A to Compound B)
Consistent crosslinking density batch after batch
Reduced material waste during production startup and changeovers
| Property | Description | Benefit |
|---|---|---|
| Excellent extrusion performance | Smooth, consistent flow through standard single-screw extruders | Reduces scrap rate; compatible with existing production lines |
| Stable physical and chemical indices | Tight control of melt flow index, density, and additive dispersion | Batch-to-batch consistency ensures reliable cable quality |
| Quick extruding speed | High output rate without sacrificing surface quality | Increases production efficiency and reduces manufacturing cost |
| Smooth surface finish | No melt fracture, no sharkskin, no surface irregularities | Improves electrical performance (reduces partial discharge risk) and aesthetic appearance |
This insulation compound is specifically designed for:
Low voltage crosslinkable wire and cable insulation
Maximum continuous working temperature: 90°C (conductor)
Maximum short-circuit temperature: 250°C (up to 5 seconds)
Typical cable types:
Power cables (0.6/1 kV)
Building wires
Control cables
Aerial bundled cables (ABC)
Solar and renewable energy cables
| Item | Unit | Test Method | Standard Value | Typical Value |
|---|---|---|---|---|
| Tensile strength | MPa | IEC 60811-1-1 | ≥ 13.5 | 18.0 |
| Elongation at break | % | IEC 60811-1-1 | ≥ 350 | 470 |
| Impact embrittlement performance @ -76°C | Failure number / piece | ASTM D746 | ≤ 15/30 | 0/30 |
| Item | Unit | Test Method | Standard Value | Typical Value |
|---|---|---|---|---|
| Tensile strength variation | % | IEC 60811-1-2 | ± 20 | +6 |
| Breaking elongation variation | % | IEC 60811-1-2 | ± 20 | -3 |
| Item | Unit | Test Method | Standard Value | Typical Value |
|---|---|---|---|---|
| Elongation under load | % | IEC 60811-2-1 | ≤ 100 | 55 |
| Permanent deformation | % | IEC 60811-2-1 | ≤ 5 | 0 |
| Item | Unit | Test Method | Standard Value | Typical Value |
|---|---|---|---|---|
| Dielectric dissipation factor | – | IEC 60250 | ≤ 0.001 | 0.0001 |
| Relative dielectric constant | – | IEC 60250 | ≤ 2.35 | 2.25 |
| Dielectric strength | MV/m | IEC 60243-1 | ≥ 25 | 37 |
| Volume resistivity | Ω·m | IEC 60093 | ≥ 1 × 10¹⁴ | 6 × 10¹⁴ |
| Gel content | % | ASTM D2765 | ≥ 60 | 66 |
Use a polyethylene-specific extruder with a standard single-stage screw
Draw ratio (L/D): 18:1 to 25:1
Other equipment parameters should be adjusted according to specific production circumstances
| Zone | Feeding Section | Compression Section | Homogenization Section | Die Section |
|---|---|---|---|---|
| Temperature Range (°C) | 160–180 | 180–190 | 190–200 | 195–205 |
Note: The above temperature profile is for reference only. Actual processing temperatures may vary depending on extruder type, screw design, and output rate. Optimization trials are recommended for each production line.
Pre-drying – Not required for this compound (moisture-resistant packaging)
Screen pack – 20–60 mesh recommended
Cooling – Water trough with ambient temperature water
Curing – Warm water bath at 70°C–90°C for 4–8 hours (depending on cable construction and wall thickness)
| Condition | Requirement |
|---|---|
| Storage temperature | Keep at room temperature (15°C – 30°C recommended) |
| Storage environment | Clean, dry, and well ventilated |
| Best before date | Use within six months from the date of production |
| After mixing Compound A and B | Use within 8 hours (to prevent premature crosslinking) |
| After opening Compound A | Use within 24 hours (reseal tightly after each use) |
Store away from direct sunlight, heat sources, and moisture
Keep bags sealed until ready for use
Do not store near solvents, acids, or alkalis
Proper storage prevents:
Moisture absorption (can cause voids and poor crosslinking)
Premature crosslinking (can lead to scorching during extrusion)
Degradation of silane coupling agent and catalyst activity
| Item | Description |
|---|---|
| Total package weight | 25 kg per combined unit (Compound A + Compound B) |
| Compound A (grafted polyethylene) | 23.75 kg per bag |
| Compound B (catalytic masterbatch) | 1.25 kg per bag |
| Inner packaging | Moisture-resistant aluminum laminated bag – provides excellent moisture barrier protection |
| Outer packaging | Composite paper bag – ensures mechanical strength during transport and handling |
| Palletizing | Palletized bottom – easy handling with forklift, stable for storage and shipping |
| Option | Description |
|---|---|
| Bulk bags | 500 kg or 1000 kg FIBC (with separate A and B components) |
| Custom labeling | OEM branding, batch number printing |
| Shrink-wrapped pallets | For export and long-distance shipping |
Each batch of compound is tested to ensure compliance with the specifications above. Routine tests include:
Tensile strength and elongation (before and after aging)
Gel content
Volume resistivity
Dielectric strength
Hot prolongation (hot set test)
Type tests are performed annually or upon customer request.
Traceability – Each bag is marked with:
Batch number
Production date
Component type (A or B)
Net weight
Non-toxic under normal processing conditions
No hazardous byproducts released during extrusion or crosslinking
Ventilation recommended during processing to remove any thermal degradation fumes
Personal protective equipment (PPE) – Gloves and safety glasses recommended during handling
| Standard | Compliance |
|---|---|
| RoHS | Compliant (no restricted hazardous substances) |
| REACH | Compliant (all substances registered) |
| Halogen content | Halogen-free (suitable for LSZH cable applications) |
